EP3603912B1 - Formwork element, formwork system and method for producing a component - Google Patents

Description

The invention relates to a shuttering element for a shuttering system having a base plate for components made of hardening potting material, a shuttering system for components made of hardening potting material and a method for producing a component from hardening potting material.

The term hardening grouting material encompasses numerous materials and in particular concrete. Components of the type in question are in particular precast concrete parts.

In the manufacture of precast concrete parts, it is known to place formwork elements on a base plate and in this way to form a formwork form, pour liquid concrete into the formwork form from above and remove the component produced after the concrete has hardened. The WO 2011/119051 A1 referenced, which discloses an apparatus and a method for producing concrete parts.

In the device according to WO 2011/119051 A1 the formwork elements are guided on or on rails. This is particularly disadvantageous when variability with regard to different shapes and sizes of the formwork is required. To increase this variability, it has long been known to use formwork elements that have a magnet. If this magnet is in an active state, for example in that it, arranged inside the formwork element, is lowered in the direction of the base plate, then the formwork element is fixed on the base plate of the formwork by means of this magnet. If the magnet is placed in an inactive state, for example by the fact that it is inside the formwork element arranged, is raised relative to the base plate, the formwork element can be moved. Such a formwork element is for example from DE 299 20 866 U1 known.

Formwork elements of the type in question are placed and fixed in the contour of the prefabricated part on the base plate, a mostly at least partially flat surface, also called the formwork surface, in appropriate positions, in particular connected with a force fit. This can be done by a screw, adhesive or welded connection or by a vacuum. Another possibility is the previously explained fixing with the aid of magnets, in particular a magnet that is integrated in the formwork element. In other words, the formwork form is open at the top, the base plate serves as the lower formwork surface for the component and the side surfaces of the formwork form are formed by the set formwork elements, whose contour thus determines the circumferential side contour of the component.

After the formwork has been built, it is filled with the potting material and after the potting material has hardened, the component is lifted out of the formwork. Here, however, there are restrictions depending on the contour of the side surfaces of the formwork and thus the side contour of the component. Removing the component upwards, for example with a crane provided for this purpose, is only possible when the formwork is in place if the side contour has no undercuts. Are there such undercuts, for example when a chamfer is provided on the component on the side that corresponds to the open-topped side of the formwork shape, which in certain components, for example precast concrete, for example a typical dimension of 10 mm x 10 mm below 45 °, then it is not possible to remove the component upwards after hardening with the formwork in place. The corresponding formwork element that forms the undercut must first be moved away from the component to the outside.

In particular, if there are undercuts in both directions perpendicular to the base plate, use of such a formwork element on both sides, in which both sides of the formwork element simultaneously serve as side surfaces of adjacent formwork forms, is excluded, since the undercut both lifts the tool and lifts it off of the formwork element and also prevents the formwork element from moving away from the component due to the adjacent component.

Robots are used in the manufacturing process in particular in the industrial production of precast concrete parts, including semi-prefabricated parts such as element ceilings and double walls, and solid parts such as solid walls, sandwich walls and solid ceilings, also in connection with setting and moving formwork elements. Such formwork robots can be moved over the base plate of a formwork system, localize formwork elements with the help of laser scanners and set them from above, fix them, release the fixation, pick up the formwork elements again and later set them again. In particular, the activation and deactivation of magnets in such formwork elements can also be carried out by the formwork robot.

In the case of the undercuts explained above, which prevent the component from being lifted out, the use of a shuttering robot, in particular in the form of a robot crane, is not possible. In a production method according to the prior art, the formwork element is therefore typically first released from its fixation by hand in such a case, with the magnet first having to be deactivated manually in the case of magnetic fixation described above, and then manually away from the component emotional. Only then can the shuttering robot, for example by means of the laser scanner, search for the shuttering element, find it in the retracted position and record, tape. This means that additional human labor is required for the manufacturing process and that it is also slowed down and made more expensive. In addition, with this manual activity, despite safety devices such as light barriers and correspondingly adapted controls of the formwork robots, there is a tendency to increase the risk of accidents for the person performing the manual activity.

A formwork element according to the preamble of claim 1 is from DE 31 47 694 A1 known.

The present invention is based on the object of providing a formwork element for a formwork system having a base plate for components made of hardening potting material, a formwork system for components made of hardening potting material and a method for producing a component made of hardening potting material, which compared to the prior art explained above in With regard to the technical problems presented in this regard are improved.

This object is achieved by a formwork element with the features of claim 1, a formwork system with the features of claim 6 and a method for producing a component according to claim 7. Advantageous embodiments of the invention are specified in the subclaims.

It is pointed out that the features listed individually in the patent claims can also be combined with one another in any desired and technologically meaningful manner and thus show further embodiments of the invention.

The formwork element according to the invention is used in a formwork system and for carrying out a method of production of a component made of hardening potting material to be used and used as described in the introduction to the description. The features in this regard, insofar as they are not changed, modified and / or supplemented by the invention, as set out below, are therefore to be regarded as components of the claimed invention.

In particular, the formwork element according to the invention can be retained on the base plate of a formwork system. Fastening means provided for this purpose can, for example, have a screw, adhesive or welded connection or a device for generating a vacuum. Another possible fastening means has at least one magnet which can be activated and deactivated with regard to its effect on the base plate, in particular by lowering and raising a magnet arranged within the formwork element.

The formwork element according to the invention has a formwork element base body, which can be held on the base plate by means of the at least one fastening means, and at least one formwork skin element that is movable relative to the formwork element base body. The movable formwork skin element can adopt a potting position by means of a movement means, in which the hardening potting material can be potted for producing the component, and a removal position in which the cured component and / or the formwork element can be removed.

The formwork element according to the invention therefore makes it possible to place the formwork element base body on the base plate and leave it there not only for the casting process and the duration of the hardening, but also to release the cast and cured component if lateral undercuts are provided, see above that, depending on the manufacturing process, lifting the component and / or lifting off the formwork element is possible without the latter having to be moved beforehand. This speeds up the manufacturing process, makes it more economical and creates additional security for the people performing the work. In addition, the formwork element according to the invention enables use on both sides even in the case of undercuts on both sides, so that several forms of formwork can be implemented on the same base plate in a more space-saving and economical manner.

The movement means can be designed in such a way that the movement of the movable formwork skin element relative to the formwork element base body from the casting position into the removal position and vice versa is preferably stepless. For the type of movement, i.e. translational, rotary or a combination thereof, and the related structural design, the movement means used for this purpose, numerous possibilities are available to the person skilled in the art, which he selects with his specialist knowledge, especially with regard to the shape of the formwork skin .

The person skilled in the art can also select the amount of movement with regard to the shape of the formwork skin, among other things. In an advantageous embodiment of the invention, the removal position is a position in which the cured component and / or the formwork element can be removed in a direction perpendicular to the base plate. This then makes it possible to carry out the removal by means of a crane or a crane-like formwork robot or demoulding robot.

With regard to the type of movement, the invention is such that the at least one movable formwork skin element can be displaced in a direction that runs parallel to the base plate when the formwork element is held ready for use on the base plate, for example by having the movement means corresponding telescopes -or have scissors elements. Another of the multitude of corresponding possibilities for structuring the movement means consists in providing at least one, preferably a plurality of longitudinally guided guide members which are guided by corresponding Actuators can be moved axially so that the at least one movable formwork skin element can be moved between a potting position and a removal position. The actuators can be driven in different ways, for example mechanically, electrically, hydraulically or pneumatically, so that the movement of the at least one movable formwork skin element takes place, depending on the selected drive type, by means of movement means that are mechanical, electrical, hydraulic, pneumatic or a combination of at least two these modes of operation are driven.

In addition, at least two movable formwork skin elements are provided, the at least two movable formwork skin elements being arranged on opposite sides of the formwork element base body. The at least two movable formwork skin elements can also be arranged on one side of the formwork element base body, a single one of these movable formwork skin elements being movable independently of the at least one further movable formwork skin element on the same side of the formwork element base body. In addition, it is possible to provide several individually movable formwork skin elements on two opposite sides of the formwork element base body.

An embodiment is particularly preferred in which the movement means are designed such that they can be activated automatically, that is to say remotely controlled and / or as a step in an automated manufacturing process, for example in connection with the functions of a shuttering robot. This allows concrete parts to be manufactured particularly quickly and economically.

The invention also comprises a formwork system for components made of hardening potting material with a base plate and with at least one formwork element according to the invention of the type explained above, this formwork system, apart from the type, nature and the use of the formwork element according to the invention can essentially correspond to the state of the art, as explained in the introduction, in particular also using a demolding robot.

According to a further aspect, the invention comprises a method for producing a component from hardening potting material using the aforementioned formwork system according to the invention with the formwork element according to the invention, according to the features of claim 7.

In an advantageous embodiment of the method according to the invention, the shuttering element and / or the component can be removed by means of a robot, in particular by means of a demolding robot, which can also release the relevant fixation on the base plate before removing the shuttering element.

The invention is explained in more detail below with reference to the figures. It should be pointed out that the figures show embodiment variants of the invention in a schematic manner. The figures show, in particular, those features that are changed, modified and / or modified by the invention compared to the prior art explained at the beginning can be added. Further, per se known features of a generic formwork element, a generic formwork system and a generic method for producing a component from hardening potting material, which the person skilled in the art knows how to supplement through his specialist knowledge and through the prior art explained at the beginning, are for reasons of clarity and compactness the representation in the figures and not shown in the following

Description of the figures not discussed or not discussed in detail.

The invention is not restricted to the variant embodiments shown. In particular, as far as it is technically sensible, the invention includes any combination of the technical features that are listed in the claims or described in the description as being relevant to the invention.

Show it:

• Fig. 1 a schematic sectional view of a formwork element according to a first embodiment of the invention with two movable formwork skin elements in a removal position,
• Fig. 2 a schematic sectional view of the formwork element according to Fig. 1 with the two movable formwork skin elements in a potting position,
• Fig. 3 a schematic perspective illustration of a formwork element with movable formwork skin elements in a removal position,
• Fig. 4 a schematic perspective view of the formwork element according to Fig. 3 with the movable formwork skin elements in a potting position,
• Fig. 5 a schematic perspective view of the formwork element according to Figures 3 and 4 with one movable formwork skin element in a potting position and the second movable formwork skin element in a removal position,
• Fig. 6 a schematic perspective illustration of a formwork element according to the invention, a movable formwork skin element in a potting position and the second movable formwork skin element in a removal position,
• Fig. 7 a schematic sectional view of a formwork element according to an embodiment of the invention with movement means having a toggle lever mechanism and two movable formwork skin elements in a removal position,
• Fig. 8 a schematic sectional view of the formwork element according to Fig. 7 and the two movable formwork skin elements in a potting position,
• Fig. 9 a first schematic sectional illustration of a formwork element according to a further embodiment of the invention with movement means having a link drive and two movable formwork skin elements in a removal position,
• Fig. 10 a second schematic sectional illustration of the formwork element according to Fig. 9 , only a section is shown, this is enlarged and the section plane perpendicular to the section plane according to FIG Fig. 9 is chosen
• Fig. 11 a first schematic sectional illustration of the formwork element according to Fig. 9 and the two movable formwork skin elements in a potting position,
• Fig. 12 a second schematic sectional illustration of the formwork element according to Fig. 11 , only a section is shown, this is enlarged and the section plane perpendicular to the section plane according to FIG Fig. 11 is chosen
• Fig. 13 a first schematic sectional illustration of a formwork element according to yet another embodiment of the invention with a rack drive via a shaft with a gear (Spindle) having movement means and two movable formwork skin elements in a removal position,
• Fig. 14 a second schematic sectional illustration of the formwork element according to Fig. 13 , only a section is shown, this is enlarged and the section plane perpendicular to the section plane according to FIG Fig. 13 is chosen
• Fig. 15 a first schematic sectional illustration of the formwork element according to Fig. 13 and the two movable formwork skin elements in a potting position, and
• Fig. 16 a second schematic sectional illustration of the formwork element according to Fig. 15 , only a section is shown, this is enlarged and the section plane perpendicular to the section plane according to FIG Fig. 15 is chosen.

Fig. 1 shows schematically in a simplified sectional view a formwork element 10 according to a first embodiment of the invention, two movable formwork skin elements 11 being in a removal position. Fig. 2 basically corresponds Fig. 1 , shows the embodiment according to Fig. 1 however, in an operating state in which the two movable formwork skin elements 11 are in a potting position. FIGS. 1 and 2 are also schematic and sketchy in that hatching, with the exception of the components 100 shown, is omitted. A base plate 50 on which the formwork element 10 is placed is only indicated by a horizontal line in the Figures 1 and 2 indicated.

In the Figures 3 to 6 are shown schematically in perspective embodiments of the formwork element 10, the formwork skin elements 11 are in different positions and are designed so that they are opposite to the Figures 1 and 2 The formwork skin elements 11 shown additionally have a bulge extending in the longitudinal direction to the outside, which is already in itself taken, that is to say without forming an undercut on the edges that leads to chamfers in the component 100.

In all of the representations, the formwork skin elements 11 are designed in such a way that the component 100 formed with them has bevels on its top and bottom. Typical components 100 of the type in question here are precast concrete parts, for example semi-finished parts such as element slabs and double walls, and solid parts such as solid walls, sandwich walls and solid slabs. A typical dimension of a bevel is 10 mm x 10 mm at 45 °. By designing the formwork skin elements 11 in such a way that such a bevel is formed on the top and bottom of the component 100, there is an undercut in both directions perpendicular to the base plate 50, which allows one of the components 100 to be raised vertically in the illustration according to Fig. 2 , in which the formwork skin elements 11 are in the potting position, as well as the formwork element 10 is not possible.

Fig. 1 In contrast, shows a removal position of the formwork skin elements 11, that is to say a position in which both one of the components 100 and the formwork element 10 can be lifted vertically.

Both in the Figures 1 and 2 as well as in the Figures 3 to 6 Movement means 13 are shown schematically, which move the formwork skin elements 11 and hold them in the respective positions. The movement means 13 indicated in the figures serve to move the formwork skin elements 11 horizontally relative to a formwork element base body 12 (see FIG Figures 3 to 6 ). It goes without saying that, depending on the circumstances, for example the design and shape of the formwork skin elements 11, the movement means can also be designed in such a way that instead of this purely translational movement, other movement sequences, in particular also with rotary Movement components such as pivoting can be realized.

The one in the Figures 3 to 6 Formwork element base body 12 shown is in the Figures 1 and 2 not shown explicitly for reasons of clarity of illustration. Instead, they show Figures 1 and 2 a fastening means 20 in the form of a magnet which can be moved vertically within the formwork element base body 12 via an actuating element 22. In the Figures 1 and 2 the fastening means 20 is shown in the form of a magnet in a lowered position in which its holding function relative to the base plate 50 is activated. If the magnet is raised via the actuating element 22 within the formwork element base body 12 and is thus brought into a sufficient distance from the base plate 50, the holding function is deactivated.

The Figures 7 to 16 show examples of possibilities for the structural design of the means of movement. In the Figures 7 to 16 are those features already associated with the Figures 1 to 6 have been given the same reference numerals and are not explained again separately below.

With the options shown according to the Figures 7 to 16 Mechanical guide members 15 in the form of rod-shaped elements are used, which can cause the formwork skin element 11 to move relative to the formwork element base body 12 via an axial bearing 16. It goes without saying that the person skilled in the art has numerous other constructive and basic possibilities available, for example telescopic elements or scissor constructions.

The three in the Figures 7 to 16 The exemplary embodiments shown differ in particular in how the sliding movement is initiated in the guide members 15.

In the example according to Figures 7 and 8 a toggle lever mechanism with a toggle lever actuator 24 and a lifting rod 23 is used for this purpose, the function of which is clear and unequivocal for the person skilled in the art results from the representations shown. The lifting movement of the lifting rod 23, which via the toggle lever actuator 24 causes an axial displacement of the guide members 15 and thus a displacement of the formwork skin elements 11 relative to the formwork element base body 12, can be performed electrically, for example via a solenoid, mechanically, for example by a lever element, pneumatically, for example via compressed air cylinders or hydraulically by means of appropriate hydraulic actuators.

In the embodiment according to Figures 9 to 12 the actuator is designed as a link drive actuator 26 which is driven via a rotary shaft 25. The embodiment according to FIGS Figures 13 to 16 uses a rotary shaft 25 as the drive element, but the actuator is designed as a rack and pinion actuator 28. The rotary shaft 25 can in turn be driven mechanically, electrically, pneumatically or hydraulically or a related combination, depending on the embodiment.

Particularly preferred is an embodiment in which the movement means 20, regardless of its specific embodiment, can be controlled automatically and / or remotely, in particular in connection with an automated manufacturing process, for example in connection with the functions of a shuttering robot. This enables a particularly fast and economical production of concrete parts.

- List of reference symbols -

10

Formwork element

11

Formwork skin element

12

Formwork element base body

13

Means of Movement

15th

Leading member

16

Thrust bearing

20th

Fasteners

22nd

Actuator

23

Lifting rod

24

Toggle actuator

25th

Rotating shaft

26th

Link drive actuator

28

Rack and pinion actuator

50

Base plate

100

Component

Claims (8)

1. Formwork element (10) for a formwork system for construction elements (100) of curing casting material, the formwork system comprising a base plate (50), comprising:

   at least one fastening means (20) for retaining the formwork element (10) on the base plate (50),

   comprising

   a formwork element basic body (12) which is adapted to be retained on the base plate (50) by means of the at least one fastening means (20),

   at least one formwork shell element (11) movable with respect to the formwork element basic body (12), and

   moving means (13) for moving the at least one movable formwork shell element (11) with respect to the formwork element basic body (12);

   wherein the at least one movable formwork shell element (11) is adapted to take a casting position by means of the moving means (13) in which a casting of the curing casting material can take place to manufacture the construction element (100), and a withdrawal position in which a withdrawal of the cured construction element (100) and/or the formwork element (10) can take place, wherein the moving means (13) is designed such that the at least one movable formwork shell element (11) is shiftable in a direction that is parallel to the base plate (50) if the formwork element (10) is retained on the base plate (50) ready to use,

   characterized in that

   at least two movable formwork shell elements (11) are arranged on one side of the formwork element basic body (12), wherein an individual one of these movable formwork shell elements (11A) is movable independent of the at least one further movable formwork shell element (11B) on the same side of the formwork element basic body (12).
2. Formwork element (10) according to claim 1, characterized in that the withdrawal position is such a position where a withdrawal of the cured construction element (100) and/or of the formwork element (10) can take place in a direction perpendicular to the base plate (50).
3. Formwork element (10) according to claim 1 or 2, characterized in that at least two movable formwork shell elements (11) are provided, wherein the at least two movable formwork shell elements (11) are arranged on opposite sides of the formwork element basic body (12).
4. Formwork element (10) according to one of the preceding claims, characterized in that the moving means (13) for moving the at least one movable formwork shell element (11) with respect to the formwork element basic body (12) comprises drive elements which have mechanical, electric, hydraulic, pneumatic mode of operation, or a combination of at least two of these modes of operation.
5. Formwork element (10) according to one of the preceding claims, wherein the fastening means (20) for retaining the formwork element (10) on the base plate (50) comprises a magnet (20) which causes, in an activated state, the retaining of the formwork element (10) on the base plate (50), characterized in that the at least one movable formwork shell element (11) is movable from the casting position to the withdrawal position if the magnet (20) is in an activated state.
6. Formwork system for construction elements (100) of curing casting material having a base plate (50) and at least one formwork element (10) according to one of the preceding patent claims 1 to 5.
7. Method for the manufacture of a construction element (100) of curing casting material using a formwork system according to claim 6 with at least one formwork element (10) according to one of the preceding claims 1 to 5, comprising the steps of:

   assembling a formwork mold using a base plate (50) and at least one formwork element (10) comprising a formwork element basic body (12) and a movable formwork shell element (11),

   fixing the at least one formwork element (10) on the base plate (50), wherein the at least one formwork shell element (11) movable with respect to the formwork element basic body (12) is in a casting position,

   pouring in liquid curing casting material into the formwork mold,

   letting the curing casting material cure,

   moving the at least one movable formwork shell element (11) into the withdrawal position,

   wherein the at least one movable formwork shell element (11) is shifted into a direction that is parallel to the base plate (50) when the formwork element (10) is retained on the base plate (50) ready to use, and

   wherein at least one individual formwork shell element (11A) of at least two movable formwork shell elements (11), arranged on one side of the formwork element basic body (12), is moved, independent of at least one further movable formwork shell element (11B), on the same side of the formwork element basic body (12), and

   withdrawing the formwork element (10) and/or the construction element (100).
8. Method according to claim 7, characterized in that the moving of the at least one movable formwork shell element (11) and/or the releasing of the formwork element (10) from its fixation, and/or the withdrawal of the formwork element (10) and/or the construction element (100) is/are done in an automated manner, in particular using a robot for removing the formwork.

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